Integrated simulation method and experimental validation for the vacuum induction melting process
In Vacuum Induction Melting (VIM), reduction of defects such as porosity and cracking is critical to improve electrode integrity. Traditional simulation method ignores the temperature drop of liquid metal as it passes through the tundish, leading to inaccuracies in predicting the solidification proc...
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| Format: | Article |
| Language: | English |
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Elsevier
2024-11-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424021884 |
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| _version_ | 1850105229477937152 |
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| author | Shu Li Zhan Zhao Tao Zhang Xin Li Tingxuan Chen He Jiang Jianxin Dong |
| author_facet | Shu Li Zhan Zhao Tao Zhang Xin Li Tingxuan Chen He Jiang Jianxin Dong |
| author_sort | Shu Li |
| collection | DOAJ |
| description | In Vacuum Induction Melting (VIM), reduction of defects such as porosity and cracking is critical to improve electrode integrity. Traditional simulation method ignores the temperature drop of liquid metal as it passes through the tundish, leading to inaccuracies in predicting the solidification process in the mold. Additionally, the crack of ingot may occur during demolding process, which is always overlooked. This paper presents an integrated simulation method that includes the flow model of liquid metal in the tundish, as well as the solidification model and the stress model of ingot in the mold. Based on these models, the criterion for demolding time is established based on First and Fourth Strength Theories. The entire VIM process from pouring to demolding can be analyzed comprehensively through this simulation method. The method is validated by 500 kg Inconel 718 VIM trial including the temperature measurement of outer mold wall, the height measurement of liquid metal in the tundish and longitudinal sectioned experiment of ingot. The suitable criteria for porosity of 500 kg Inconel 718 ingot, including shrinkage porosity and shrinkage cavity, have been found to be the Niyama criterion threshold of 15 K0.5s0.5cm−1 and Classical porosity model. Finally, the impact of each process parameter on porosity and demolding time is studied through this method for 500 kg Inconel 718 ingot. This method is not only applied to 500 kg ingot but also to larger ingot, thereby providing a basis for the VIM process optimization. |
| format | Article |
| id | doaj-art-53fdd35396554bfeb38e6e514ad2c1bd |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-53fdd35396554bfeb38e6e514ad2c1bd2025-08-20T02:39:09ZengElsevierJournal of Materials Research and Technology2238-78542024-11-01331764177510.1016/j.jmrt.2024.09.183Integrated simulation method and experimental validation for the vacuum induction melting processShu Li0Zhan Zhao1Tao Zhang2Xin Li3Tingxuan Chen4He Jiang5Jianxin Dong6School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaCorresponding author.; School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, ChinaIn Vacuum Induction Melting (VIM), reduction of defects such as porosity and cracking is critical to improve electrode integrity. Traditional simulation method ignores the temperature drop of liquid metal as it passes through the tundish, leading to inaccuracies in predicting the solidification process in the mold. Additionally, the crack of ingot may occur during demolding process, which is always overlooked. This paper presents an integrated simulation method that includes the flow model of liquid metal in the tundish, as well as the solidification model and the stress model of ingot in the mold. Based on these models, the criterion for demolding time is established based on First and Fourth Strength Theories. The entire VIM process from pouring to demolding can be analyzed comprehensively through this simulation method. The method is validated by 500 kg Inconel 718 VIM trial including the temperature measurement of outer mold wall, the height measurement of liquid metal in the tundish and longitudinal sectioned experiment of ingot. The suitable criteria for porosity of 500 kg Inconel 718 ingot, including shrinkage porosity and shrinkage cavity, have been found to be the Niyama criterion threshold of 15 K0.5s0.5cm−1 and Classical porosity model. Finally, the impact of each process parameter on porosity and demolding time is studied through this method for 500 kg Inconel 718 ingot. This method is not only applied to 500 kg ingot but also to larger ingot, thereby providing a basis for the VIM process optimization.http://www.sciencedirect.com/science/article/pii/S2238785424021884SuperalloyVacuum induction meltingIntegrated simulation methodPorosityDemolding |
| spellingShingle | Shu Li Zhan Zhao Tao Zhang Xin Li Tingxuan Chen He Jiang Jianxin Dong Integrated simulation method and experimental validation for the vacuum induction melting process Journal of Materials Research and Technology Superalloy Vacuum induction melting Integrated simulation method Porosity Demolding |
| title | Integrated simulation method and experimental validation for the vacuum induction melting process |
| title_full | Integrated simulation method and experimental validation for the vacuum induction melting process |
| title_fullStr | Integrated simulation method and experimental validation for the vacuum induction melting process |
| title_full_unstemmed | Integrated simulation method and experimental validation for the vacuum induction melting process |
| title_short | Integrated simulation method and experimental validation for the vacuum induction melting process |
| title_sort | integrated simulation method and experimental validation for the vacuum induction melting process |
| topic | Superalloy Vacuum induction melting Integrated simulation method Porosity Demolding |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424021884 |
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